|Publication number||US5578227 A|
|Application number||US 08/113,241|
|Publication date||Nov 26, 1996|
|Filing date||Aug 30, 1993|
|Priority date||Aug 30, 1993|
|Also published as||WO1998022253A1|
|Publication number||08113241, 113241, US 5578227 A, US 5578227A, US-A-5578227, US5578227 A, US5578227A|
|Inventors||Joshua E. Rabinovich|
|Original Assignee||Rabinovich; Joshua E.|
|Export Citation||BiBTeX, EndNote, RefMan|
|Patent Citations (29), Non-Patent Citations (2), Referenced by (107), Classifications (17), Legal Events (3)|
|External Links: USPTO, USPTO Assignment, Espacenet|
The complexity of modern systems such as weapons, aircraft, ground transportation and the demands for their rapid development and qualification has resulted in the escalation of costs associated with their successful and timely introduction.
A revolutionary improvement in the cost and time of development of these systems could be realized if prototype models, scaled or full scale, of critical system components could be rapidly produced and subjected to proof testing.
Furthermore, the ability to conduct tests of these critical components early in their development would allow many more iterations of a design to be conducted in a short time, thus significantly improving the system's reliability, allowing early incorporation/evaluation of the system maintainability features, and significantly reducing the overall development time and cost.
There are three major 3-Dimensional model rapid prototyping methods currently available:
a. Photocurable liquid solidification or Stereolithography.
b. Selective Laser Sintering (SLS) or powder layer sintering.
c. Fused Deposition Modeling (FDM) or extruded molten plastic deposition method.
The above methods use geometric data from numerous currently available Computer Aided Design (CAD) solid modeling systems. This data is imported into a rapid prototyping system. A computer generated solid model is sliced into horizontal layers that are used as input for control of the rapid prototyping system.
Stereolithography is currently the most popular rapid prototyping method. Stereolithography generates a 3-D model by directing a laser beam onto the surface of a vat of liquid photocurable polymer. An elevator table in the polymer vat rests just below the liquid's surface. A laser beam is directed onto the polymer surface and solidifies it at the point of laser beam impingement. After a part slice at one depth has been made by scanning the laser beam back and forth in the shape of the model or pattern to be developed, the elevator platform upon which the model is being constructed drops the programmed amount. Another layer or slice is then created on top of the first in the same manner.
The process continues until the complete model has been constructed. After the construction phase is completed a curing process in a special curing apparatus is necessary.
The photocurable liquid plastics currently used in stereolithography are limited to acrylic plastics and produce parts with low strength and poor dimensional stability, especially during the transition through the curing process.
Selective Laser Sintering (SLS) generates a 3-D model by directing a laser beam onto a thin layer of plastic powder deposited on a target surface. The first layer corresponds to a first cross-sectional region of the part. The powder is sintered by operating the directed laser energy within the boundaries defining the first layer. A second layer of plastic powder is deposited on the first sintered layer, and the aim of the laser beam is scanned within the boundaries defining the second layer. Successive portions of powder are deposited onto the previously sintered layers until the complete model has been constructed.
A larger selection of plastic powder materials is used in this method. Plastics like PVC, Nylon, Polycarbonate and Wax are used. The part's quality and dimensional stability are sensitive to the powder moisture content and powder purity which strongly influence the laser beam energy absorption and powder sintering process. The parts produced by this method have poor dimensional stability and poor strength at relatively low temperatures.
Fused Deposition Modeling (FDM) generates a 3-D model by depositing extruded molten plastic in successive thin laminations in a pattern within the boundaries defining the part's layers. The material then solidifies as it is directed into place with an X-Y controlled extruding head nozzle that creates a thin laminate.
The thermoplastic melt temperature must be maintained within one degree Fahrenheit above the solidification point to secure proper adherence to the previous layer.
The materials used in the Fused Deposition Modeling method are limited to wax and plastic material with a melting temperature below 220 degrees Fahrenheit.
All of the above mentioned rapid prototyping methods are limited to applications for the prototype form evaluation or as a model used in further industrial processes, such as investment casting. The quality of these prototypes in terms of accuracy and dimensional stability is strongly dependent on particular qualities of the plastic materials used in the process and the process variations.
The accuracy of the 3-D models and their dimensional stability is also strongly dependent on process variations such as temperature of the processed plastic and its chemical purity and moisture content.
Those materials are limited to plastics with low melting temperatures and limited physical characteristics. The 3-D models produced with these rapid prototype methods have very poor strength, ductility and dimensional stability over time.
These material limitations make the previously existing methods unsuitable for producing prototype models which would have the materials of construction identical or close to the materials used in the final product. Therefore, the 3-D models produced on these systems are not suitable for model functional testing in the majority of cases.
A need exists for new and improved prototype modeling.
A new rapid prototyping system is based on fusion of a thin feedstock of metal and nonmetal materials which have various profiles, for example a rectangular-wire.
The new system generates a three-dimensional model by dispensing a feedstock, for example a thin strip of stainless steel, onto a substrate. The feedstock is fused to the substrate in a succession of overlying laminations, each having the thickness of the feedstock, and in a pattern within the boundaries defining the part's layers. Successive layers are deposited onto the previously fused layers until the complete model has been constructed.
The feedstock fusion is performed with a laser beam of the size and power density sufficient for reliable spot or continuous welding of the feedstock to the previous layer while keeping the feedstock cross section in substantially original shape.
The first layer corresponds to a first cross-sectional region of the part. The first layer is constructed by moving the substrate with the fused portion of the feedstock in the X-Y plane and relative to the axis along the laser beam and the feedstock point of contact with the substrate.
The substrate movements in the X-Y plane trace the boundary and interior of each cross-sectional region of the desired part. The feedstock dispensing nozzle is rotatable around the laser beam axis which allows the positioning of the feedstock delivery axis always in a direction tangential to the boundary curvature at any point in time. When the continuity of the feedstock must be interrupted, the deposited laser energy is increased to the level sufficient for cutting the feedstock.
The basic approach taken here solves major problems inherent in previous methods, and allows for achieving the quality target specifications detailed below.
The rapid prototyping system of the invention is capable of producing solid models out of a wide range of metal and nonmetal materials. Materials such as Ni-Cr stainless steel alloys, glass, polypropylene and polyethylene are readily available in the form of wire, fibers or strips, and have been laser welded and cut with excellent results.
Each layer's deposition is performed with a limited local heat input, thus insuring maximum dimensional stability of the 3-D model. No post curing is involved in this method.
The model's dimensional accuracy is significantly above the accuracy of the models made by stereolithography. The control of the feedstock deposition can be compared to the accuracy of the tool path of conventional numerical controlled machines.
The present system provides a method for rapid production of prototypes which have the materials of construction identical or close to the materials used in the final product.
The model's strength, dimensional accuracy and thermal stability are significantly higher than models made by prior art methods. Therefore the 3-D models produced on the system of the invention are suitable for functional testing.
The prototype system of the invention combines commercially available components using a personal computer, X,Y and Z positioning stages, rotary stage, step-motor controller cards with standard software utilities. A CO2 sealed laser system is employed.
A model building method includes fusing thin feedstock of metal and nonmetal materials which have various profiles, with a laser beam of a size and power density sufficient for a reliable spot or continuous weld of the feedstock to a previous layer while keeping the feedstock cross section in substantially original shape, producing a limited local heat input, and inducing a high accuracy and dimensional stability of a 3-D model, and good surface quality of the model results.
A substrate is moved in an X-Y plane and tracing the boundary and interior of each cross-sectional region of a desired part.
A feedstock dispensing nozzle is rotated around the laser beam axis.
The feedstock delivery axis is continuously positioned in a direction tangential to a boundary curvature of the model.
The feedstock is concurrently fed while fusing the feedstock.
A 3-D model building method includes feeding through a feedstock dispensing nozzle to a desired location a thin feedstock of metal and nonmetal materials which have various profiles. The feedstock is fused with a laser beam of a size and power density for producing a limited local heat input sufficient for a reliable spot or continuous welding of the feedstock to a previous fused layer while keeping the feedstock cross section in substantially original shape. A high accuracy and dimensional stability is produced, and a good surface quality of the 3-D model results.
A substrate on which the layer is produced is moved in X-Y directions on a plane transverse to the laser beam, and tracing the boundary and interior of each cross-sectional region of a desired part beneath the feeding of the feedstock. The feedstock dispensing nozzle is rotated around an axis of the laser beam. A delivery axis of the feedstock is continuously positioned in a direction tangential to the boundary curvature at a point where the feedstock is being fused to a previous layer.
The laser beam is formed by directing a linearly polarized beam from a laser source to a phase shifting mirror. The linearly polarized beam is converted to a circularly polarized laser beam at the mirror, and the circularly polarized beam is directed to a lens which focuses the beam to a spot on the feedstock.
The feedstock is stored on a spool, is drawn from the spool and is forced into the dispensing nozzle with a feedstock drive. The feedstock is curved in the dispensing nozzle before releasing the feedstock from the nozzle. Introducing nitrogen in the nozzle and releasing nitrogen from the nozzle near the feedstock floods the fusing.
The spool, the feedstock drive, the nozzle and the lens are rotated as an assembly around an axis of the laser beam. The axis of the laser beam and the assembly are moved along a line on which the feedstock is to be fused. The assembly is turned about the axis as the line curves, and the lens is moved and a beam spot is traversed across the feedstock for cutting the feedstock.
A preferred model building apparatus includes a frame. A laser beam source and a phase shift mirror are mounted on the frame. A feedstock delivery module support is also mounted on the frame. A rotary stage is mounted on the feedstock delivery module support, and a rotary arm is mounted on the rotary stage. A feedstock feeder is mounted on the rotary arm, and a laser beam focusing lens is mounted on the rotary arm. A feedstock storing spool is mounted on the rotary arm, and a flat wire feedstock is stored on the spool. A feedstock nozzle is connected to the rotary arm for receiving feedstock from the spool and feeder and for extending feedstock from a tip of the nozzle. The tip of the nozzle is aligned with a laser beam projected from the laser source to the mirror and through apertures in the support, rotating arm and rotary stage and through lens. A rectangularly movable stage is positioned beneath the nozzle for receiving feedstock in a predetermined pattern according to relative movement of the stage in an X-Y direction in relation to the frame. Feedstock extending from the nozzle tip is fused to a substrate or to previously fused layers of the feedstock for constructing a model by depositing and fusing successive layers of the feedstock.
The spool and the rotary stage and the lens are aligned on an axis of the laser beam.
The feeder has pinch rollers driven by a stepper motor.
The lens is mounted in a mount which is pivoted transverse to an axis of the laser beam. A driver is mounted on the rotary arm and is connected to the lens mount for moving the lens mount about the pivot for traversing a laser beam spot across the feedstock to cut the feedstock.
An inert gas passageway is mounted in the nozzle for flooding an intersection of the feedstock and the laser beam with inert gas during fusing of the feedstock.
The laser source produces a linearly polarized beam. The mirror converts the linearly polarized beam to a circularly polarized beam. The circularly polarized beam is focused by the lens on the feedstock which has just been released from the nozzle.
The nozzle has a feedstock passageway with a radius in the passageway near the tip of the nozzle for bending the feedstock in a radius to release the feedstock flat with the substrate or previous fused layer of feedstock.
A computer has a multi axis controller for controlling the rectilinearly movable stage.
A model making method and apparatus projects a linearly polarized laser beam from a laser source onto a mirror for circularly polarizing the beam and directing the circularly polarized beam vertically toward a rectilinearly movable stage for fusing a rectangular wire to a substrate or a previously fused wire layer on the stage. The circularly polarized beam projects through a center of a spool and a rotary stage and through a support for the rotary stage and a rotary arm which is mounted on the rotary stage. The rotary arm supports a stepper feeder which draws the wire from the spool and pushes the wire through the nozzle. The nozzle radiuses the wire so that it lies flat as the wire is released near a focused spot of the circularly polarized laser beam. The rotating arm carries a lens mount on a pivot so that the lens which focuses the beam may traverse the wire for cutting the wire. Movement of the rectilinearly movable stage in a X-Y direction is controlled by a computer and stepper motors to follow a predetermined pattern of a cross-section of the model. The rotary arm turns on the rotary stage to release the wire tangentially to curvatures in the model outline. After each complete layer, the stage is stepped downward one wire thickness, and the next layer is formed. The nozzle includes a gas jet passage for flooding the wire with inert gas as it is fused.
These and further and other objects and features of the invention are apparent in the disclosure, which includes the above and ongoing written specification, with the claims and the drawings.
FIG. 1 schematically illustrates the main system components.
FIG. 2 schematically shows the dispensing nozzle.
FIG. 3 is a partial side elevation of a root portion of a model of a turbine blade constructed by the present invention.
FIG. 4 is a sectional end view of the turbine blade shown in FIG. 3.
FIG. 5 shows a computer used with the present invention.
The preferred system includes the following major modules: beam delivery module 50; feedstock material delivery module 60; workpiece table module 70 and CAD/CAM data generation and the system control module 80.
Referring to FIG. 1, the beam delivery module 50 includes a CO2 laser 1 with a linearly polarized output beam 2, a phase shift mirror 3, a circularly polarized output beam 4 and an image lens 5.
The feedstock material delivery module 60 includes a rotary stage 11 on a fixed support bed 13. In a preferred embodiment, bed 13, laser source 1 and mirror 3 are mounted on a fixed frame. Alternatively, a movable frame supports a movable support bed 13 which moves with the laser generator and mirror 3 along the desired path, which follows the outline of the model layer being constructed. Spool 6 contains feedstock supply material 7, for example in the form of 304 stainless steel rectangular wire strip 0.010 inch thick by 0.020 inch wide. The feedstock 7 is pulled from the independently rotatable spool and is propelled through the dispensing arm 8 by means of a feed drive mechanism 9. The drive 9 pushes the feedstock through the dispensing nozzle 10, from which the feedstock is delivered onto the substrate 12.
Inert gas like nitrogen is delivered to the point of fusion through the line 16 and the nozzle 20, as shown in FIG. 2.
The dispensing arm 8, the feed drive mechanism 9, the dispensing nozzle 10 and the image lens 5 are connected in one unit assembly 17 which is rotatable by the controlled rotary stage 11 around the axis of the laser beam 4. The optical center of the image lens 5 coincides with the geometrical center of the beam 4.
The workpiece table module 70 consists of X,Y,Z axis stage 3, which supports substrate 12.
The CAD/CAM data generation and the system control module 80, as shown in FIG. 5, includes an IBM PC compatible 486 microprocessor based computer 14 with a multi axis controller and I/O card 18.
The system's CAD/CAM uses as input geometric data from currently available CAD solid modeling systems in the form of STL files.
The graphics module slices the 3-D CAD model into thin successive cross sectional layers. The slices correspond to the feedstock profile thickness, for example 010 inch, to be used in the construction of the part. On the basis of the cross sections the graphic module produces the toolpath in a form similar to numeric control machines G-code. The part example used for the description of the system operation is an aircraft compressor blade 19. The blade's root section is shown in FIG. 3 and FIG. 4, which shows sections A--A, B--B, C--C and D--D.
The tool path is generated by following the boundaries of the pattern defining the part's layers. The tool path is achieved by simultaneous motions of the workpiece table in the X and Y axis and of the dispensing nozzle by rotation around the axis of the laser beam 4.
The system generates a three-dimensional model by dispensing the feedstock strip 7 onto a substrate. A laser beam 4 of a spot size approximately 0.006 inch (0.15 mm) diameter is directed onto the strip at its point of contact with the substrate 12. The feedstock is fused onto the substrate in a succession of overlying laminations each having the thickness of the feedstock, and in the pattern within the boundaries defining the part's layers.
The first layer corresponds to the first cross-section of the part. It is constructed by moving the substrate with the fused portion of the feedstock in the X-Y plane and relative to the axis along the laser beam and the feedstock point of contact with the substrate.
The substrate movement in the X-Y plane traces the boundary and interior of each cross-section of the desired part. The feedstock dispensing nozzle is rotatable around the laser beam axis, allowing positioning of the feedstock delivery axis always in a direction tangential to the boundary curvature of each cross-section.
A small scanning stroke (0.020") of the image lens across the feedstock material allows the feedstock cutting operation. The scanning is performed by the deflection of the image lens holder/flexure 15 perpendicular to the feedstock orientation. The magnets 22 and 23 provide the necessary stroke. The indent in the lens holder and the ball and spring arrangement 24 provide the fixation of the lens holder in the neutral position, as shown in FIG. 1.
Successive layers are deposited onto the previously fused layers until the complete model has been constructed.
The system can be constructed with multiple feedstock materials for example a stainless steel strip and an organic or inorganic strip of material having the same thickness and each having its own dispensing nozzle. Each cross section can be built by alternating the material inside of the cross section. Thus the production of a composite material model is possible.
The beam delivery module 50 includes a Coherent Model DIAMOND 64 CO2 laser with power output of 150 W in the prototype system. The high quality of the laser results in a small focused spot which yields high power densities. That results in a small heat affected zone (HAZ), which minimizes heat spread to adjacent material. Combined with the laser's small size and its sealed design, that laser makes an excellent choice for the system.
Because of a linear polarization of the laser beam and the dependency of the laser cutting and welding properties on the material's orientation in relationship to the beam polarization plane, the use of a phase shift mirror is desirable. A phase shift mirror transforms a beam with linear polarization into a beam with circular polarization, which allows a consistent welding and cutting operation regardless of the material's orientation.
To obtain a circularly polarized beam from one of the mirrors, two angles have to be correctly set, as shown in FIG. 1. The phase shift mirror 3 is positioned with an incidence angle of 45 degrees. The laser beam output 2 with a plane of polarization parallel to the laser base is rotated 45 degrees to the plane of incidence.
The resulting circularly polarized beam is focused with the image lens 5 (F=2.5 inch) into a desired small spot on the image plane which lays at the point of impingement of the laser beam with the feedstock top surface. A Melles Griot Zinc Selenide Positive Lens with focal distance of 63.5 mm (2.5 inches) is used for the image lens 5.
The feedstock material delivery module 60 uses an AEROTECH rotary stage ART300 Series equipped with a stepper motor with an encoder and a home marker, and having a stage resolution of 0.1 arc minute. The rotary stage is provided with an aperture at its center of rotation to allow the laser beam to pass through. The following subassemblies are attached to the rotary stage.
A feedstock spool 6 stores a 0.010"×0.020" flat wire. A flat wire feed mechanism 9 extracts a continuous wire from the spool and delivers the wire through the dispensing nozzle 10 to the substrate for subsequent fusion. The feed mechanism includes friction rollers 25 driven by a stepper-motor and encoder Escap P300 series. The feed speed is controlled by the system controller.
The feedstock dispensing nozzle 10 incorporates a wire guide groove of the shape and dimensions which will allow a sliding movement of the flat wire inside the dispensing nozzle. The tip of the nozzle is positioned slightly above the top surface of the current layer, as shown in FIG. 2. The end of the nozzle has a radial shape which induces a radial shape to the flat wire to deliver it tangentially to the substrate.
That feature allows the initial close contact of the flat wire with the substrate during initialization of the wire fusion process. This close contact is important for a successful welding operation. Close contact with the substrate or the previous layers is maintained at all times because of the wire straightening forces which are induced by the substrate motion away from the dispensing nozzle tip.
The feed of the flat wire should be synchronized with and correspond to the speed of the substrate motion around the cross-section boundary at any given moment. Initially the system may be maintained at a constant speed around the boundary.
The workpiece table module 70 uses an AEROTECH Precision X-Y-Z AT0200 Series stage. The stage is driven by stepper motors equipped with encoders.
The system control module 80 uses a Delta Tau Data System PMAC-NC motion controller. The PMAC's capabilities are ideally suited for use in Computer Numerical Control (CNC) machine tools. The PMAC-NC controller supports the traditional CNC machine G-Code. The PMAC-NC-M software package enables a host IBM PC computer to be programmed as a CNC controller. The controller is multi axis with the capabilities of 8-axis simultaneous control of the AEROTECH X-Y-Z linear motion stage, the rotary stage and the Escap P300 stepper motor of the flat wire feed mechanism. An eight position I/O card such as OPTO-22 can be connected directly to the PMAC, allowing control of the image lens scanning actuators and the nitrogen flow control solenoid valve.
The system's CAD/CAM data generation module uses as input geometric data from currently available CAD solid modeling systems in the form of .STL files.
The graphic module slices the 3-D CAD model into thin successive cross sectional layers. These correspond to the feedstock profile thickness that are to be used in the construction of the part.
While the invention has been described with reference to specific embodiments, modifications and variations of the invention may be constructed without departing from the scope of the invention, which is defined in the following claims.
|Cited Patent||Filing date||Publication date||Applicant||Title|
|US1533300 *||Nov 12, 1920||Apr 14, 1925||Westinghouse Electric & Mfg Co||Method of making decorative articles|
|US3156968 *||Mar 22, 1962||Nov 17, 1964||Jr William D White||Pressure roller and method of manufacture|
|US3558846 *||Mar 15, 1967||Jan 26, 1971||Mitsubishi Heavy Ind Ltd||Method of and apparatus for constructing substantially circular cross section vessel by welding|
|US3737616 *||Apr 2, 1971||Jun 5, 1973||Mitsubishi Heavy Ind Ltd||Apparatus for manufacturing spherical metallic vessels or hemispherical vessel heads|
|US3821840 *||Nov 29, 1972||Jul 2, 1974||Teegarden P||Railway frog repair method and apparatus|
|US3952180 *||Dec 4, 1974||Apr 20, 1976||Avco Everett Research Laboratory, Inc.||Cladding|
|US4323756 *||Oct 29, 1979||Apr 6, 1982||United Technologies Corporation||Method for fabricating articles by sequential layer deposition|
|US4575330 *||Aug 8, 1984||Mar 11, 1986||Uvp, Inc.||Apparatus for production of three-dimensional objects by stereolithography|
|US4743733 *||Oct 1, 1984||May 10, 1988||General Electric Company||Method and apparatus for repairing metal in an article|
|US4803334 *||Nov 16, 1987||Feb 7, 1989||Westinghouse Electric Corp.||Method for laser beam welding metal matrix composite components|
|US4841617 *||Aug 11, 1988||Jun 27, 1989||R. & G. Schmole Metallwerke Gmbh & Co. Kg||Method for producing heat exchanger tubes|
|US4857693 *||Dec 22, 1987||Aug 15, 1989||Jero Incorporated||Method of forming stub ends|
|US4863538 *||Oct 17, 1986||Sep 5, 1989||Board Of Regents, The University Of Texas System||Method and apparatus for producing parts by selective sintering|
|US4931125 *||Oct 16, 1987||Jun 5, 1990||The Dow Chemical Company||Method for adhesive bonding with pretreatment of components|
|US4947463 *||Feb 16, 1989||Aug 7, 1990||Agency Of Industrial Science & Technology||Laser spraying process|
|US5038014 *||Dec 1, 1989||Aug 6, 1991||General Electric Company||Fabrication of components by layered deposition|
|US5121329 *||Oct 30, 1989||Jun 9, 1992||Stratasys, Inc.||Apparatus and method for creating three-dimensional objects|
|US5134569 *||Jun 26, 1989||Jul 28, 1992||Masters William E||System and method for computer automated manufacturing using fluent material|
|US5147587 *||Feb 19, 1991||Sep 15, 1992||Board Of Regents, The University Of Texas System||Method of producing parts and molds using composite ceramic powders|
|US5208431 *||Sep 9, 1991||May 4, 1993||Agency Of Industrial Science & Technology||Method for producing object by laser spraying and apparatus for conducting the method|
|US5233150 *||Jan 17, 1992||Aug 3, 1993||Sulzer Brothers Limited||Method of production of workpieces by welding equipment|
|US5266139 *||Oct 2, 1992||Nov 30, 1993||General Dynamics Corporation, Space Systems Division||Continuous processing/in-situ curing of incrementally applied resin matrix composite materials|
|US5303141 *||Mar 22, 1993||Apr 12, 1994||International Business Machines Corporation||Model generation system having closed-loop extrusion nozzle positioning|
|CA678500A *||Jan 21, 1964||N. Connoy Eugene||Band saw blade stock and method of making the same|
|DE3905684A1 *||Feb 24, 1989||Aug 30, 1990||Ulrich Prof Dr Ing Draugelates||Build-up welding process|
|FR2583333A1 *||Title not available|
|JPH0299286A *||Title not available|
|JPH04288974A *||Title not available|
|WO1988006564A1 *||Mar 4, 1988||Sep 7, 1988||Thomson-Csf||Process for ensuring the adhesion of fibres on an unwinding bobbin|
|1||"Laser Solves Spotwelding Problems" by Schaffer in pp. 337-340 of Source Book on Electron Beam and Laser Welding, Mar. 1983.|
|2||*||Laser Solves Spotwelding Problems by Schaffer in pp. 337 340 of Source Book on Electron Beam and Laser Welding, Mar. 1983.|
|Citing Patent||Filing date||Publication date||Applicant||Title|
|US5837960 *||Nov 30, 1995||Nov 17, 1998||The Regents Of The University Of California||Laser production of articles from powders|
|US5993554 *||Jan 22, 1998||Nov 30, 1999||Optemec Design Company||Multiple beams and nozzles to increase deposition rate|
|US6027326 *||Oct 28, 1997||Feb 22, 2000||Sandia Corporation||Freeforming objects with low-binder slurry|
|US6046426 *||Jul 8, 1996||Apr 4, 2000||Sandia Corporation||Method and system for producing complex-shape objects|
|US6056839 *||Jan 8, 1998||May 2, 2000||Xerox Corporation||Rapid electrostatographic belt treatment system|
|US6068722 *||Jan 8, 1998||May 30, 2000||Xerox Corporation||Seam stress release in flexible electrostatographic imaging belts|
|US6074504 *||Jan 8, 1998||Jun 13, 2000||Xerox Corporation||Defocused laser seam stress release in flexible electrostatographic imaging member belts|
|US6129872 *||Aug 29, 1998||Oct 10, 2000||Jang; Justin||Process and apparatus for creating a colorful three-dimensional object|
|US6144008 *||Nov 22, 1996||Nov 7, 2000||Rabinovich; Joshua E.||Rapid manufacturing system for metal, metal matrix composite materials and ceramics|
|US6153034 *||Aug 3, 1998||Nov 28, 2000||Micromod R.P. Ltd||Rapid prototyping|
|US6268584||Jul 20, 1998||Jul 31, 2001||Optomec Design Company||Multiple beams and nozzles to increase deposition rate|
|US6270388 *||Jun 23, 1999||Aug 7, 2001||Samsung Display Devices Co., Ltd.||Method for fabricating partition of plasma display panel|
|US6391251||May 9, 2000||May 21, 2002||Optomec Design Company||Forming structures from CAD solid models|
|US6401795 *||Jan 3, 2000||Jun 11, 2002||Sandia Corporation||Method for freeforming objects with low-binder slurry|
|US6405095||May 25, 1999||Jun 11, 2002||Nanotek Instruments, Inc.||Rapid prototyping and tooling system|
|US6441338||Apr 10, 2000||Aug 27, 2002||Joshua E. Rabinovich||Rapid manufacturing of steel rule dies and other 3-dimensional products, apparatus, process and products|
|US6443352||Sep 27, 2000||Sep 3, 2002||Solidica, Inc.||Electrical resistance based object consolidation|
|US6455804 *||Dec 8, 2000||Sep 24, 2002||Touchstone Research Laboratory, Ltd.||Continuous metal matrix composite consolidation|
|US6457629||Oct 4, 2000||Oct 1, 2002||Solidica, Inc.||Object consolidation employing friction joining|
|US6519500||Mar 23, 2000||Feb 11, 2003||Solidica, Inc.||Ultrasonic object consolidation|
|US6552299 *||Nov 19, 2001||Apr 22, 2003||Carl Baasel Lasertechnik Gmbh||Laser-processing unit with observation device|
|US6643560 *||Sep 30, 2002||Nov 4, 2003||Incs Inc.||Data generating device, data generating method and data generating program|
|US6656409||Jul 7, 2000||Dec 2, 2003||Optomec Design Company||Manufacturable geometries for thermal management of complex three-dimensional shapes|
|US6706998||Jan 8, 2003||Mar 16, 2004||Electro Scientific Industries, Inc.||Simulated laser spot enlargement|
|US6727459||Feb 28, 2003||Apr 27, 2004||Liburdi Engineering Limited||Method for metal deposition on an edge|
|US6811744||Apr 22, 2002||Nov 2, 2004||Optomec Design Company||Forming structures from CAD solid models|
|US6814823||Sep 15, 2000||Nov 9, 2004||Solidica, Inc.||Object consolidation through sequential material deposition|
|US6989507 *||Jan 27, 2004||Jan 24, 2006||Rolls-Royce Plc||Laser deposition|
|US7001672||Mar 26, 2004||Feb 21, 2006||Medicine Lodge, Inc.||Laser based metal deposition of implant structures|
|US7168935 *||Aug 1, 2003||Jan 30, 2007||The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration||Solid freeform fabrication apparatus and methods|
|US7270679||Feb 18, 2004||Sep 18, 2007||Warsaw Orthopedic, Inc.||Implants based on engineered metal matrix composite materials having enhanced imaging and wear resistance|
|US7276298||Nov 30, 2004||Oct 2, 2007||Samsung Sdi Co., Ltd.||Substance for intermediate layer of organic electroluminescent device and organic electroluminescent device using the same|
|US7384255||Jul 1, 2005||Jun 10, 2008||Stratasys, Inc.||Rapid prototyping system with controlled material feedstock|
|US7600666||May 27, 2003||Oct 13, 2009||Rabinovich Joshua E||Repair with feedstock having conforming surfaces with a substrate|
|US7620527||May 9, 2000||Nov 17, 2009||Johan Leo Alfons Gielis||Method and apparatus for synthesizing and analyzing patterns utilizing novel “super-formula” operator|
|US7632575||Oct 18, 2005||Dec 15, 2009||IMDS, Inc.||Laser based metal deposition (LBMD) of implant structures|
|US7666522||May 10, 2006||Feb 23, 2010||IMDS, Inc.||Laser based metal deposition (LBMD) of implant structures|
|US7851984||Aug 8, 2006||Dec 14, 2010||Federal-Mogul World Wide, Inc.||Ignition device having a reflowed firing tip and method of construction|
|US7879394||Jun 1, 2007||Feb 1, 2011||Optomec, Inc.||Deep deposition head|
|US7951412||Jan 17, 2007||May 31, 2011||Medicinelodge Inc.||Laser based metal deposition (LBMD) of antimicrobials to implant surfaces|
|US8132744||Apr 15, 2010||Mar 13, 2012||Optomec, Inc.||Miniature aerosol jet and aerosol jet array|
|US8319151||Feb 17, 2010||Nov 27, 2012||Siemens Medical Instruments Pte. Ltd.||Method to manufacture a hearing aid with indirect laser exposure|
|US8334475 *||Nov 4, 2009||Dec 18, 2012||Rabinovich Joshua E||Process for energy beam solid-state metallurgical bonding of wires having two or more flat surfaces|
|US8389896||Feb 18, 2010||Mar 5, 2013||Siemens Medical Instruments Pte. Ltd.||Rapid prototyping device and method with indirect laser exposure|
|US8455051||Dec 22, 2010||Jun 4, 2013||Optomec, Inc.||Apparatuses and methods for maskless mesoscale material deposition|
|US8775134||Oct 20, 2009||Jul 8, 2014||Johan Leo Alfons Gielis||Method and apparatus for synthesizing and analyzing patterns|
|US9089999 *||Aug 17, 2012||Jul 28, 2015||Nike, Incorporated||Method and apparatus for manufacturing components used for the manufacture of articles|
|US9114409||Sep 25, 2012||Aug 25, 2015||Optomec, Inc.||Mechanically integrated and closely coupled print head and mist source|
|US9317627||Jul 6, 2014||Apr 19, 2016||Genicap Beheer B.V.||Method and apparatus for creating timewise display of widely variable naturalistic scenery on an amusement device|
|US9586357 *||Jun 22, 2012||Mar 7, 2017||Stratasys, Inc.||Ribbon filament and assembly for use in extrusion-based digital manufacturing systems|
|US9607889||Aug 1, 2014||Mar 28, 2017||Optomec, Inc.||Forming structures using aerosol jet® deposition|
|US20020030680 *||May 31, 2001||Mar 14, 2002||Leica Microsystems Heidelberg Gmbh||Method and system for generating a three-dimensional object|
|US20030033049 *||Sep 30, 2002||Feb 13, 2003||Incs Inc.||Data generating device, data generating method and data generating program|
|US20040182844 *||Jan 27, 2004||Sep 23, 2004||Rolls-Royce Plc||Laser deposition|
|US20040238508 *||May 27, 2003||Dec 2, 2004||Rabinovich Joshua E.||Low heat input laser component repair or joining with feedstock having conforming surfaces with a substrate|
|US20040243241 *||Feb 18, 2004||Dec 2, 2004||Naim Istephanous||Implants based on engineered metal matrix composite materials having enhanced imaging and wear resistance|
|US20050133527 *||Nov 2, 2004||Jun 23, 2005||Optomec Design Company||Powder feeder for material deposition systems|
|US20050136288 *||Nov 30, 2004||Jun 23, 2005||Soo-Hyoung Lee||Substance for intermediate layer of organic electroluminescent device and organic electroluminescent device using the same|
|US20050173380 *||Feb 9, 2005||Aug 11, 2005||Carbone Frank L.||Directed energy net shape method and apparatus|
|US20060003095 *||May 3, 2005||Jan 5, 2006||Optomec Design Company||Greater angle and overhanging materials deposition|
|US20060049153 *||Sep 8, 2004||Mar 9, 2006||Cahoon Christopher L||Dual feed laser welding system|
|US20070003656 *||Jul 1, 2005||Jan 4, 2007||Stratasys, Inc.||Rapid prototyping system with controlled material feedstock|
|US20070287027 *||Jan 17, 2007||Dec 13, 2007||Medicinelodge, Inc.||Laser based metal deposition (lbmd) of antimicrobials to implant surfaces|
|US20080036353 *||Aug 8, 2006||Feb 14, 2008||Federal-Mogul World Wide, Inc.||Ignition device having a reflowed firing tip and method of construction|
|US20090188894 *||Jan 28, 2008||Jul 30, 2009||Honeywell International Inc.||Welding guide nozzle including nozzle tip for precision weld wire positioning|
|US20100155374 *||Nov 4, 2009||Jun 24, 2010||Rabinovich Joshua E||process for energy beam solid-state metallurgical bonding of wires having two or more flat surfaces|
|US20100206860 *||Feb 17, 2010||Aug 19, 2010||Tze Peng Chua||Method to manufacture a hearing aid with indirect laser exposure|
|US20100224605 *||Feb 18, 2010||Sep 9, 2010||Siemens Medical Instruments Pte. Ltd.||Rapid prototyping device and method with indirect laser exposure|
|US20100228381 *||Mar 1, 2010||Sep 9, 2010||Sony Corporation||Three-dimensional modeling apparatus and three-dimensional object|
|US20100292968 *||Oct 20, 2009||Nov 18, 2010||Johan Leo Alfons Gielis||Method and apparatus for synthesizing and analyzing patterns|
|US20110052412 *||Oct 10, 2007||Mar 3, 2011||Mtu Aero Engines Gmbh||High-pressure turbine rotor, and method for the production thereof|
|US20110057554 *||Nov 17, 2010||Mar 10, 2011||Zdeblick William J||Ignition Device Having a Reflowed Firing Tip and Method of Construction|
|US20110190923 *||Jan 14, 2011||Aug 4, 2011||Sony Corporation||Three-dimensional modeling apparatus, method of manufacturing a three-dimensional object, and three-dimensional object|
|US20120258190 *||Jun 22, 2012||Oct 11, 2012||Stratasys, Inc.||Ribbon filament and assembly for use in extrusion-based digital manufacturing systems|
|US20120306125 *||Aug 17, 2012||Dec 6, 2012||Nike Inc.||Method and Apparatus for Manufacturing Components Used for the Manufacture of Articles|
|US20130255346 *||Mar 12, 2013||Oct 3, 2013||A. Raymond Et Cie||Metal-stamping die manufactured by additive manufacturing|
|US20140190942 *||Aug 8, 2012||Jul 10, 2014||Bae Systems Plc||Forming a layered structure|
|US20140202999 *||Aug 8, 2012||Jul 24, 2014||Andrew David Wescott||Forming a structure|
|US20150128602 *||Nov 12, 2014||May 14, 2015||Rolls-Royce Deutschland Ltd & Co Kg||Heat shield for a gas turbine combustion chamber|
|US20150343664 *||May 27, 2014||Dec 3, 2015||Jian Liu||Method and Apparatus for Three-Dimensional Additive Manufacturing with a High Energy High Power Ultrafast Laser|
|US20160067778 *||Jul 3, 2014||Mar 10, 2016||Jian Liu||Method and Apparatus for Three-Dimensional Additive Manufacturing with a High Energy High Power Ultrafast Laser|
|DE102008028109A1 *||Jun 13, 2008||Dec 24, 2009||Eads Deutschland Gmbh||Verfahren und Vorrichtung zur Herstellung von verstärkten Bauteilen|
|DE102015002967A1 *||Mar 7, 2015||Oct 13, 2016||Willi Viktor LAUER||3D-Druckwerkzeug und 3D-Druck von Bündeln|
|EP0895850A1 *||Aug 3, 1998||Feb 10, 1999||Micromod R.P. Ltd.||Rapid prototyping|
|EP1005941A2 *||Nov 26, 1999||Jun 7, 2000||Rolls-Royce Limited||Method and appparatus for building up a workpiece by deposit welding|
|EP1005941A3 *||Nov 26, 1999||Oct 17, 2001||Rolls-Royce Limited||Method and appparatus for building up a workpiece by deposit welding|
|EP1164405A2 *||May 30, 2001||Dec 19, 2001||Leica Microsystems Heidelberg GmbH||Method and device to generate a three dimensional object|
|EP1164405A3 *||May 30, 2001||Oct 27, 2004||Leica Microsystems Heidelberg GmbH||Method and device to generate a three dimensional object|
|EP1454703A1 *||Jan 15, 2004||Sep 8, 2004||ROLLS-ROYCE plc||Laser deposition|
|EP1491281A2 *||Feb 27, 2004||Dec 29, 2004||Liburdi Engineering Limited||Method for metal deposition on an edge of a metallic substrate|
|EP1491281A3 *||Feb 27, 2004||Nov 23, 2005||Liburdi Engineering Limited||Method for metal deposition on an edge of a metallic substrate|
|EP3093921A1||Mar 15, 2013||Nov 16, 2016||The Antenna Company International N.V.||Lens antenna, method of manufacturing and using such an antenna, and antenna system|
|WO1998055257A1 *||Jan 22, 1998||Dec 10, 1998||The Regents Of The University Of California||Production of elongated articles from particulates|
|WO2001007239A1 *||Jun 26, 2000||Feb 1, 2001||Fraunhofer Gesellschaft zur Förderung der angewandten Forschung e.V.||A device and method for the preparation of building components from a combination of materials|
|WO2001093785A2||Jun 5, 2001||Dec 13, 2001||Laser Fare||Orthopedic implant and method of making metal articles|
|WO2001093786A2||Jun 5, 2001||Dec 13, 2001||Tensegra, Inc.||Orthopedic implant and method of making metal articles|
|WO2005077586A1 *||Feb 4, 2005||Aug 25, 2005||Aquasium Technology Limited||Method of manufacturing three-dimensional products through deposits of successive layers of a wire melted by electron beam|
|WO2007005236A1 *||Jun 15, 2006||Jan 11, 2007||Stratasys, Inc.||Rapid prototyping system with controlled material feedstock|
|WO2007126565A1 *||Mar 9, 2007||Nov 8, 2007||The Boeing Company||Method and system for toolpath generation|
|WO2012140658A3 *||Apr 5, 2012||Jun 18, 2015||Stratasys Ltd.||System and method for layer by layer printing of an object with support|
|WO2013174449A1||May 25, 2012||Nov 28, 2013||European Space Agency||Multi-wire feeder method and system for alloy sample formation and additive manufacturing|
|WO2014046537A1||Mar 15, 2013||Mar 27, 2014||The Antenna Company International N.V.||Lens antenna, method of manufacturing and using such an antenna, and antenna system|
|WO2014046538A1||Mar 15, 2013||Mar 27, 2014||The Antenna Company International N.V.||Lens antenna, method of manufacturing and using such an antenna, and antenna system|
|WO2015147635A1||Feb 3, 2015||Oct 1, 2015||The Antenna Company International N.V.||Patch antenna, method of manufacturing and using such an antenna, and antenna system|
|WO2016033343A1 *||Aug 27, 2015||Mar 3, 2016||Nuburu, Inc.||Applications, methods and systems for materials processing with visible raman laser|
|WO2016164729A1 *||Apr 8, 2016||Oct 13, 2016||President And Fellows Of Harvard College||Inline laser sintering of metallic inks|
|WO2017027784A1 *||Aug 12, 2016||Feb 16, 2017||Corning Incorporated||Method and system for printing 3d objects|
|U.S. Classification||219/121.63, 156/272.8, 219/76.14, 156/180, 219/121.64|
|International Classification||B23K26/34, B29C67/00|
|Cooperative Classification||B33Y30/00, B33Y10/00, B23K2203/50, B23K26/32, B23K26/324, B29C67/0074, B29C2791/005, B23K26/34|
|European Classification||B23K26/34, B29C67/00R4|
|Jan 5, 2000||FPAY||Fee payment|
Year of fee payment: 4
|Apr 20, 2004||FPAY||Fee payment|
Year of fee payment: 8
|Mar 20, 2008||FPAY||Fee payment|
Year of fee payment: 12